Method and system for the electronic provision of services for machines via a data communication link

ABSTRACT

With this invention, expert knowledge from machine manufacturers is applied quickly at any time to a machine ( 20 ) via the Internet, by providing a main computer (host  8 ) for the production and provision of machine-related data and/or services and a machine-side working computer (client  21 ), which is connected to the main computer via a data communication link ( 14 ) and by means of which (client) machine state data can be acquired in real time and transmitted to the main computer, and by means of which machine-related data and/or services generated by the main computer as a function of such machine state data can be received by means of an analysis and evaluation unit.

The invention relates to a system for computer-aided handling andmanagement of a numerically controlled industrial processing machine,and an apparatus and a corresponding method for computer-aided provisionof machine-related data and/or services.

In the area of industrial automation technology and, in particular, inthe field of numerically controlled processing machines, manufacturersoffer service in the form of control technology and correspondingsoftware components for other manufacturers of original accessories(Original Equipment Manufacturer, OEM), who manufacture and marketindustrial processing machines.

Such OEMs generally have good relationships with their end-customers,who are often themselves manufacturers of accessories and operate themachines and their accessories acquired from the OEMs.

Such OEMs not only develop and market goods such as machine tools, but,going beyond this, also offer service for the products which they andothers sell to end-customers. Since the marketed products are generallyhighly complex, there are high requirements for, and difficulties in,the provision of such services, for which a large amount of informationis needed with reference to the operation of their machine tools.

The significant difficulties in the provision of such services consistin obtaining access to information needed for the service of themachines to be maintained. In this case, this also concerns to a greatextent items of information that have to be obtained directly from theprocessing process of the machine tools. Appropriate software componentsfor such machine tools or other industrial processing machines aregenerally highly specialized in terms of the implementation of theactual control task. With regard to the acquisition of machine datagoing beyond this, however, for the reasons mentioned above, beyond theimmediate control of the machine, no further machine information isconventionally provided.

For these and other reasons, manufacturers of numerical control systemsand corresponding software components for industrial processing machineswere not in a position to supply performance improvements on suchmachines to their end-customers, directly or via OEMs, on the basis ofknowledge-based information.

For this reason, there is a great need, on the basis of such ongoingmachine state data, primarily for maintenance and service purposes, tomake services and machine-related know-how available to end-customers asquickly as possible and at any location. As a result, the availabilityof such machines, their lifetime and their productivity may bedecisively improved.

Previously, no methods or apparatus have been disclosed on the basis ofwhich either services or software components could be developed thatwould permit services based on collected machine data. These would alsopermit automated services that were formerly not possible to implement.Moreover, it has not previously been possible to provide servicestailored specifically to the processing machine of an end-customerwithin a reasonable time frame, since the capacities of the serviceproviders are generally inadequate to do so.

For this reason, it is conventional for service personnel withcorresponding know-how to be dispatched to the end-customer in order to:analyze the machine, physically and manually while on-site, andtherefore primarily in response to specific requirements of theend-customers; to obtain appropriate machine data on-site; and, on thisbasis, to offer the corresponding maintenance or services.

In this way, however, it is not possible to offer real-time related, orparticularly computationally-intensive, services such as axis analyses,for example, or other optimization, machine calibration, softwareservices, machine data management or other dynamic intervention in themachine.

It is precisely this, however, that would be particularly important forend-customers in order for them to shorten their development times, toincrease their market presence and to ensure maximum availability of themachines.

It is therefore an object of the present invention to provide a methodand a corresponding apparatus which, without a physical presenceon-site, also make available particularly computationally-intensive dataor services from a manufacturer or provider of accessories for themachine of an end-customer.

According to the present invention, this object is achieved by a systemfor computer-aided handling and management of a numerically-controlledindustrial processing machine, having the following features:

-   a main computer (host) to produce and provide machine-related data    and/or services and-   a machine-side working computer (client), which is connected to the    main computer via a data communication link and by means of which    (client) machine state data can be acquired in real time and    transmitted to the main computer, and by means of which    machine-related data and/or services generated by the main computer    as a function of such machine state data can be received by an    analysis and evaluation unit.

In this case, it has proven to be beneficial if the main computer has acommunication link to a higher-order computer system of a machinemanufacturer or a manufacturer of machine components, via which accessto system data of the main computer can be granted to the higher-ordercomputer system by the main computer. In this way, service routines, inparticular software components, and the computing capacity of such acomputer, can be used for the analysis of captured the machine data.

If the machine-side working computer (client) has a uniqueidentification means with respect to the main computer (host), inparticular an identification code, then the main computer (host) canassociate machine state data received from this working computer withthis working computer. In this way, comprehensive archives withmachine-related data from various end-customers and machines can begenerated, which can be used, for example, for statistical purposes orto construct a fault history.

The data communication link between the main computer (host) and theworking computer (client) is advantageously a connection via an Internetor Intranet.

Here, it is possible for the determination of machine state data on thepart of the working computer (client) to be controlled via instructionsreceived from the main computer (host) via the Internet or Intranet.

This succeeds particularly effectively if Internet pages or Intranetpages for the user-aided selection of options provided therein can betransmitted from the main computer (host) to the working computer(client).

Furthermore, the object of the invention is also achieved by a methodfor computer-aided production and provision of machine-related dataand/or services for a numerically-controlled industrial processingmachine, a main computer (host) and a machine-side working computer(client) communicating via a data communication link, having thefollowing method steps:

-   acquisition of machine state data on the part of the working    computer (client),-   transmission of the acquired machine state data via the data    communication link to the main computer (host),-   generation of machine-related data and/or services on the part of    the main computer (host) as a function of such machine state data    and-   provision of these machine-related data and/or services to the    working computer (client) or its user.

Here, it has proven to be particularly beneficial if machine state dataare acquired in real time on the part of the working computer (client).

Here, too, the advantages already mentioned with regard to dataarchiving can be achieved by a unique identification means, inparticular an identification code, associated with the machine-sideworking computer (client) being transmitted to the main computer (host).To this end, the main computer (host) associates machine state datareceived from a working computer to this working computer by using theidentification means.

In this way, the creation of a database with machine-related data for aplurality of industrial processing machines is enabled, whereby a commonmain computer (host) performing computer-aided generation and provisionof machine-related data and/or services, as described above, for aplurality of working computers (clients) is associated with theindustrial processing machines, and whereby a data set with the machinestate data from one of the working computers (clients) is generated in astorage means and the unique identification code associated with thisworking computer is determined, and an item of information correspondingto the identification code is appended to the data set.

The machine state data preferably comprise program data, servo data,motor data, converter data, position data or sensor data. Furthermore,however, depending on the application, additional machine state data canalso be determined.

According to a further advantageous refinement of the method of thepresent invention, the working computer (client) buffers the acquiredmachine state data in a storage means before the data are transmitted tothe main computer (host).

Such a transmission of machine state data stored in the storage means ispreferably carried out via the data communication link to the maincomputer (host) under time control or event control. Furthermore, it isadvantageous if automatic analysis or evaluation of received machinestate data is carried out on the part of the main computer (host).

The object of the invention is further achieved by a method forcomputer-aided provision of machine-related data and/or services from amain computer of a service provider to a working computer of aprocessing machine of a customer via a network, the working computer ofthe processing machine of the customer having a system for the controland/or monitoring of the processing machine and a suitable sensor foracquiring machine state data and being connected to the network, havingthe following method steps:

-   transmission of information relating to the availability of    machine-related data and/or services from the main computer to the    working computer,-   receipt of a request for machine-related data and/or a service from    the working computer on the part of the main computer,-   transmission of information with reference to requisite machine    state data to be acquired by the working computer from the main    computer to the working computer,-   receipt of data from the working computer containing the requisite    machine state data on the part of the main computer,-   generation of the machine-related data requested by the working    computer and/or the requested service by the main computer and-   transmission of the machine-related data requested by the working    computer and/or the requested service from the main computer to the    working computer.

In order to register the cost incurred by the services provided, it isfurther advantageous if the main computer receives and storesinformation with respect to a payment for requested machine-related dataand/or services from the working computer. In order to register priceinformation for payment, the following further method steps haveadditionally proved to be beneficial:

-   determination of a first item of price information as fixed costs of    a predetermined repeated time period, in particular a monthly time    period,-   determination of a second item of price information as variable    costs as a function of a service provided.

For the computer-aided provision of services for optimization purposes,according to a further advantageous embodiment of the invention, thefollowing further method steps are carried out:

-   generation of a data structure to accommodate data with reference to    a service,-   storage of first data in the data structure, which represent the    identity of a customer, in particular of the unique identification    code, and-   storage of further data in the data structure, which represent the    identity of the service.

Here, the following further method steps have proven to be advantageous:

-   determination of measured data with reference to the service    provided to the customer and-   storage of further data in the data structure, which represent these    measured data.

Furthermore, the object of the invention is achieved by an apparatus forcomputer-aided provision of machine-related data and/or services on amain computer of a service provider for a working computer of aprocessing machine of a customer via a network, in particular with asystem for computer-aided handling and management of a numericallycontrolled industrial processing machine as outlined above, the workingcomputer of the processing machine of the customer having a system forthe control and/or monitoring of the processing machine and a suitablesensor for acquiring machine state data and being connected to thenetwork, having the following further main computer features:

-   a means for transmitting    -   information relating to the availability of machine-related data        and/or services from the main computer to the working computer        and    -   information with reference to requisite machine state data to be        acquired by the working computer from the main computer to the        working computer and    -   the machine-related data requested by the working computer        and/or the requested service from the main computer to the        working computer and-   a means for the receipt    -   of a request for machine-related data and/or a service from the        working computer on the part of the main computer and    -   of data from the working computer containing the requisite        machine state data on the part of the main computer and-   a means for generating the machine-related data requested by the    working computer and/or the requested service by the main computer.

This may be implemented particularly effectively if the means forgenerating the machine-related data requested by the working computerand/or the requested service by means of the main computer comprises anInternet web server and the main computer is suitably programmed to useit to produce Internet web pages.

Here, too, it is advantageous if the working computer of the customerhas a unique identification means, in particular an identification code,for the processing machine and if the main computer has a storage means,in particular a database, to accommodate information from the workingcomputer in conjunction with the identification code.

Finally, the object of the invention is also achieved by means of anapparatus for computer-aided provision of services for an automationsystem via a network, in particular with a system, described above, forcomputer-aided handling and management of a numerically controlledindustrial processing machine, having the following features:

-   a means for loading instructions into the automation system, the    instructions controlling at least one function or another aspect of    the automation system,-   a means for receiving customer-related system data from the    automation system via the network, such system data being collected    as a function of the loaded instructions,-   a means for generating suitable services for the automation system    as a function of the collected customer-related system data and-   a means for transmitting such services to the automation system of    the customer via the network.

Here, it has proved to be beneficial if a means for providing aselection of options of the service is provided on the automation systemof the customer via the network. This, likewise, applies to a means forselecting one of the options of the service on the part of theautomation system of the customer.

Further advantages are obtained if the automation system has a networkinterface for communication via the network and for receiving theservice information, and a means (machine agent) is provided forgenerating machine-executable program sequences on the basis of thereceived services, the network interface and the means for generatingmachine-executable program sequences exchanging data via a predefineddata format. This succeeds particularly effectively if the networkinterface comprises an Internet browser.

The above-described method according to the invention may be usedparticularly well for remote commissioning or remote maintenance of anindustrial working machine.

In addition, a use is also recommended for implementing a subset of thefollowing measures:

-   electronic measurement of workpieces, tools and clamping means for    the diagnosis of problems in the event of deficient workpiece    quality or for the dialog-guided correction of the relationships,-   indication of the relationships of process variables such as laser    output, feed speed or tool rotational speed and feed speed,-   analysis of the tool paths in the Cartesian coordinate system, with    correction or statements relating to a good part/poor part,-   monitoring of process variables with limiting value monitoring    and/or correlation monitoring,-   program analysis by processing a program in a virtual simulation of    the processing machine,-   automatic creation of commissioning logs for the seamless    documentation of the commissioning state,-   automatic creation of service and maintenance logs for the seamless    documentation of the machine history,-   evaluation for the diagnosis of exceptional and fault situations,-   saving and archiving configuration data, user data and programs for    the reconstruction of states or for the detection of changes    affected by problems.

Such an online service according to the invention, also referred tobelow as an ePS network (electronic production services) improves themachine availability for the manufacturers and increases theavailability of the machines for the users.

The E-business infrastructure according to the invention permits themachine manufacturers to maintain the machines of their customerssignificantly more simply and more efficiently. All ePS services arecarried out with high online safety.

ePS services which are offered to the machine users are based onminimizing the operating costs, increasing the lifetime of the machine,improving the product quality, increasing productivity and ensuringmaximum availability of the production means.

Further advantages and details of the present invention emerge by usingthe exemplary embodiments illustrated in the following text and inconjunction with the figures. In each case in a basic representation:

FIG. 1 shows a block diagram of a system according to the invention forproviding automated services via a network, and also alternative orsupplementary manual services,

FIG. 2 shows a block diagram of a system according to the presentinvention for providing automated services and/or data to anend-customer via a network,

FIG. 3 shows a block diagram of an advantageous embodiment according tothe invention,

FIG. 4 shows a further block diagram of a client-server architecturebased on the present invention with emphasis on the client/workingcomputer side,

FIG. 5 to FIG. 7 show various phases and parameters for carrying out acircular shape test with a system according to the invention.

The representation according to FIG. 1 shows, at a high level ofabstraction, how, on the basis of an Internet connection, automaticservices AS or data contents or software components required for thispurpose are made available to a plurality of end-customers havingmachines S1 . . . SN, with which information is exchangedbi-directionally. In addition, a conventional provider MS of manualservices or engineering services (e.g. OEM) is shown, who likewisecommunicates with the final customers and their machines S1 . . . SN,but in a conventional way. The drawback with such an arrangement or sucha system is that no communication takes place between the provider ofthe Internet-based automatic services and the provider of conventionalmanual services. As a result, it is not possible for the technicalexpertise available on both sides to be used.

The representation according to FIG. 2 shows, in the left-hand area ofthe figure, the conventional production chain or supplier chain ofmachine tools. A supplier 2 of an automation product, who acceptsresponsibility for the control hardware and software, markets hisproducts and services to a customer, as a rule, a machine tool OEM 3.The OEM, for his part, constructs the actual machine tool on the basisof the control systems acquired with additional, self-manufactured orpurchased components. This machine tool is normally marketed toend-customers 4, as they are known, who are generally fabricationcompanies.

A provider 1 of the automated services according to the invention on thebasis of a network, in particular an Internet connection, is generallyin mutual communication with all three of the aforementioned parties. Aprovider 1 of automated services according to the invention ispreferably also in contact with further providers of software tools 5 orspecific services 6 and also with further Internet partners 7 (cf.right-hand area of the figure).

FIG. 3 now shows a more detailed representation of the main actors 1, 3and 4 from FIG. 2. The service provider 1 has an e-business maincomputer or host 8, which communicates with a system or customerdatabase 9 and is operated by an interactive user 10. Via an openapplication programming interface 11 (API), as it is known, an OEMpartner 3 is permitted access to the data content provided by the maincomputer 8.

A further interactive user 12 on the side of the OEM partner 3 can, inthis way, profit from access to the aforementioned customer data or thecustomer database 9, as will be explained in more detail later. Thispreferably takes place by means of communication by means of a maincomputer or host 13 on the side of the OEM partner 3, via a networkconnection, for example an Internet connection 14. For this purpose,measures are preferably used for secure communication, for exampleencryption methods (channel encryption or asymmetric documentencryption) and also methods of securing data integrity (for examplegeneration of hash values).

On the end-customer side 4, via appropriate interfaces, components 15 to19 are connected to the network, for example the Internet connection 14,and, therefore, to the systems of the service provider 1 and the OEMpartner 3. These components on the end-customer side 4 may be bothcomponents to be maintained and components that supply data (for exampleCNC/PLC systems 15, peripheral devices or sensors 16, controllers 17,workstation computers or PCs 18 or main computers/hosts 19).

The representation according to FIG. 4 now shows the structural andfunctional relationship according to the present invention between aclient system or working computer 21 belonging to an end-customer and amain computer 8 of a service provider, and also an exemplary machinetool 20. In this case, particular emphasis is placed on the technicalimplementation on the part of the client/working computer of anend-customer. The client system or the working computer 21 of theend-customer comprises, inter alia, a controller with a human-machineinterface (HMI), that is to say the area of the controller with which amachine operator interacts. Via this interface, access to variousapplications is granted. In addition, a numerical controller NC isprovided, which comprises a control unit NCU and a control core NCK.

The controller of the human-machine interface 21 of the working computerhas a bidirectional communication link to the main computer 8 of theprovider of automated services via a network, preferably via an Internetconnection 14. This is preferably provided via an Internet browser 23,which runs on the software layer of the operating system of the workingcomputer and via which Internet pages—web pages, as they are known—canbe loaded from the main computer 8.

A machine operator can, in a conventional way, access an Internet page,in order to request specific data contents from the main computer. Themain data transfer takes place from the main computer 8 to the Internetbrowser 23. Stimulated by reactions of a machine operator, the selectionof specific options or parameters, for example, associated informationis then transported back to the main computer 8 via the Internetconnection 14 (for example the world-wide-web WWW). In this phase of thecommunication between working computer 21 and main computer 8, however,no control-related data are, as yet, transmitted to the main computer 8.

Furthermore, the working computer/client 21 also has a machine serviceprogram or machine agent 22, which likewise executes in the context ofthe human-machine interface and the numerical control and is in aposition to accept command instructions from the main computer side 8and to generate machine-executable jobs 24, 25, as they are known, whichcan be executed directly by the numerical controller. For this purpose,the machine agent 22 is connected to the actual machine tool 20, a robotor the like via a control interface 27 (NC interface).

The machine agent 22 and the browser 23 communicate via a machine agentinterface 26, which converts services or data loaded from the maincomputer 8 via the browser 23 into a machine-executable format.Machine-executable jobs 24, 25 generated in this way can include bothinstructions to execute one or more machine-tool commands to be carriedout by the numerical controller, and also instructions to acquireavailable machine state data or other control-related data. Dataacquisition can be carried out on the basis of already existing sequencetracking, as it is known, or trace functionality, of known machine-toolsystems. Within the scope of the present invention, however, improvedtrace functionalities for acquiring machine state data can also beimagined, and will be presented at a later point.

For safety reasons, it is also possible to imagine that the initiationof machine-tool commands assumes some manual release by a machineoperator. Acquired machine state data can then be transmitted to themain computer 8 from the machine agent 22 in conjunction with a job andthe sequence of such jobs to be processed. Such a data transfer isindicated in the context of FIG. 4 by the upper arrows, which run onlyfrom left to right. Such a transfer is therefore preferablyunidirectional and does not necessarily have to comprise a communicationlink via the Internet; instead, it is also possible to imagine anydesired other network link, for example by means of a remote access, asit is known, to a local network LAN belonging to the service provider 1.

In this connection, the object is primarily to select a secure and,above all, also a fast communication link. This is because it is notalways possible to ensure that machine state data, which are primarilyacquired in real time and only arrive at the service provider with aconsiderable delay on the side of the main computer 8, can be processedquickly enough to generate the requested data or services in good timeand transmit them back to the working computer 21.

On the part of the main computer 8 of the service provider 1, a largenumber of various types of associated data or services can be producedfor the owner or operator of the working computer 21, as a function ofthe received machine state data. Possible examples are listed below.

For this purpose, a concrete implementation of an ePS service mentionedat the beginning and based on the present invention will be described.

The CNC/PLC machine equipment (PLC stands for programmable logiccontroller) is connected to the ePS server via the Internet. Machinedata from the production process are depicted in real time via the ePSserver and are compressed, analyzed and assessed there. The resultsobtained from these data with respect to machine condition, machineutilization, process stability, workpiece quality and the long-termstate changes in the machine that are to be derived, are transmitted tothe customer via the Internet.

The ePS system offers an open programming interface (API) for user andmanufacturer. As a result, ePS customers can also integrate their ownapplication/machine know-how in the form of an e-service. ePS customerscan activate their desired e-services online from the ePS service rangevia the machine controller or via a PC.

The ePS service range comprises, for example, the following e-services:

-   Machine services-   Machine performance-   Workpiece services-   Data management-   e-sales.

The ePS service “machine services” supports the commissioning (CAR,computer-aided runoff) and fault analysis in the event of service.

Via the “machine performance” service, the variance of the results ofthe cyclically repeated CAR messages can be shown. The e-service“workpiece services” secures the process stability and the workpiecequality via the real-time acquisition of the machine data. Furthermore,with this service, early detection of weak points is made possible byway of visualizing NC programs and their processing in the controller.The weak points, thus detected even before processing, can beeliminated.

Data management is a web-based archiving and management service forcontrol data, such as NC programs, machine data and parameters. Thesedata are useful, in particular, to customers who do not have their ownEDP infrastructure. This service makes it possible for the customer toresume production quickly with high data integrity in the event of theirown data losses.

Given the increasing complexity of machines and higher dependencebetween machine components and electrical equipment components, machineusers (end-customers) and even machine manufacturers, rapidly run upagainst their limits when it is a case of increasing the productivity,the accuracy, the quality, or the process stability of themachine/plant.

To increase the productivity, the accuracy, the quality or the processstability of a machine/plant, a person with expert knowledge (in aspecial field) is typically sent to the machine site. In rare cases, apoint-to-point connection from the automation component (for example acontroller) via a modem to a computer at the machine manufacturer ismade, and the expert at the machine manufacturer attempts to perform theoptimization or elimination of faults via a “remote human machineinterface”.

The following business models then solve this described problem on thebasis of the present invention using the previously described system. Inthis case, a distinction can be drawn between a business model (A) andthe provision of services (B) via a business model, for example businessmodel (A).

Business model A comprises, for example, the following measures:

-   -   recording (real-time) data (for example program data, servo        data, motor data, converter data, positions, sensor data) by        means of an automation component; subsequent storage of these        data in a memory;    -   subsequent transmission of the data from the memory (for example        under time control or event control) via the Internet into a        computer (evaluation and analysis unit); subsequent        evaluation/analysis/measurement of these data in a computer        (generally automated and not carried out by people);    -   then a reaction/response via various transmission paths (for        example via the Internet, via e-mail, via mobile phone, via        beeper, via radio, via telephone, etc.); then, if appropriate,        closure of the “control loop” by recording (real-time) data (for        example program data, servo data, motor data, converter data,        positions, or sensor data).

Via such, or similar, business model, for example business model (A),the following services (B) can then be provided.

By evaluation, analysis and measurement of these data in a computer, forexample, the following are meant:

-   -   Electronic measurement of workpieces, tools and clamping means        (from the recorded (real-time) data and not by measuring the        physically present workpiece), firstly for the diagnosis of        problems in the event of defective workpiece quality (as a        result of excessive overruns, unstable controller conditions,        faulty corrections, etc.), and, secondly, for the dialog-guided        correction of the relationships.    -   Indicating the relationships of process variables, for example        laser output and feed speed, or tool rotational speed and feed        speed. From these evaluations, conclusions can be inferred about        process quality, fabrication tolerances, etc. and, if necessary,        corrected. In the case of a satisfactory state of the tool        (Well-focused laser, satisfactory milling tool state and        geometry), a stable process can be documented. A stable process        simultaneously means a stable result. Accordingly, in many cases        subsequent measurements can be forestalled, or problems        detected, without having to wait for measured results.    -   Analysis of the tool paths (in particular on non-Cartesian        machine tools) in the Cartesian coordinate system with possible        correction or statement relating to a good part/poor part. For        instance, in many parallel kinematic machines, geometric fault        sources in the joints are not accessible for measurement. Such        faults lead to the tool tips being moved incorrectly in        geometric terms. Such problems can be recognized and corrected        via redundant measuring systems.    -   Monitoring of process variables with limiting value monitoring        and/or correlation monitoring. Assessment of the limiting        values/correlations with expert systems and correction or        process termination.    -   Program analysis by executing a program in a virtual CNC        (including interpolation data, position controller data)        following objectives: optimizing the running time, optimizing        the workpiece quality, optimizing the tool change, monitoring        collisions, monitoring geometric data, etc.    -   Automatic creation of commissioning logs for the seamless        documentation of the commissioning state. Here, a series of        measurements, such as circular shape tests, positional        measurements, measurement of speed profiles, drive currents and        torques, is carried out. These show, first of all, the        satisfactory state of the machine during the commissioning.        Second, they serve as an “electronic fingerprint” of the        machine, which is suitable to detect wear-induced changes in the        machine during operation in good time. The measurements that        form the electronic fingerprint may be combined into a macro,        and can then be repeated periodically in an identical way in the        form of batch jobs, as they are known (diagnostic batch).    -   For instance, a periodically repeated circular shape test can be        used to detect loose or cyclic faults as a result of wear of the        recirculating ball screw or of gearboxes or other force        transmission mechanisms, such as toothed belts, etc.

An example of such a circular shape test, which is carried out via thedescribed ePS system according to the invention, is represented in FIG.5 to FIG. 7, whereby in each case the machine state data being acquiredand present on the side of the main computer, and communicated to theprovider of the automatic service “circular shape test” via theInternet, are produced graphically. In this way, either a specialist atthe manufacturer can perform the required actions on the machinemanually, or this can preferably likewise be carried out automaticallyvia an electronic service via the Internet connection, such that, ifrequired, appropriate correction parameters are transmitted to theworking computer.

To this end, the measurement method and then the plane to be tested,x-y, x-z or z-y, is first selected (cf. FIG. 5 with selection of the x-yplane). Further on, the parameters for performing the circular shapetest are predefined. These are, in particular, the diameter D, center C,tolerance band T, feed speed F and direction (in the clockwise orcounterclockwise direction), which defines the predefined circular pathP (cf. FIG. 6).

FIG. 7 shows the actual position values, determined by means of theaforementioned parameters, of the circle described by the machine, thatis to say the measured contour M, which may deviate from the ideal pathP. In addition, a possible shift C-offset with respect to the specifiedcenter C of the circle is indicated. There is, then, the possibility ofarchiving the resultant data, it being possible for this purpose for thedata to be linked with an identification code I of the machine testedand possibly also of the end-customer.

On the basis of the irregularities determined in this way, it is thenautomatically possible, by means of appropriate software from themanufacturer, to generate corrective measures and, as an automaticservice, to perform an adaptation or compensation of the causativeparameters or components of the machine.

Irregularities of the axle guidance systems can be detected by means ofan irregular current waveform or speed waveform (waviness measurements).Instabilities of the position controller resulting from alteredfrictional conditions can be discerned by observing dynamic positionalbehavior (overshooting). The object of the measurements is, for example,to avoid wear-induced stoppages of the machine, as a result of the factthat the wear is detected early and in an automated manner (long-termwear diagnosis); and affected parts can be procured in good time (forexample by means of automatic orders via e-sales) and can be replacedduring planned maintenance periods.

If external measuring means are used (for example a ball bar or lasermeasuring system), a further object is to calibrate internal measuringsystems in order to be able to dispense with external measuring means inthe case of repeated measurements.

For example, in the case of a circular shape test, which uses only themotor measuring system, looseness in gearboxes or in the recirculatingball screw cannot be readily detected in this way, but can be seen veryeasily by using a ball bar. If a plurality of parameters are recordedsimultaneously (for example overrun and currents in additional to themeasuring system), looseness can nevertheless be detected, assumingappropriate inertial conditions.

From the comparison between one and the same measured variable fromdifferent sources (for example external distance measured signal, linearscale or motor measuring system), far-reaching conclusions may be drawnas to the machine state.

-   -   Automatic creation of service and maintenance logs for the        seamless documentation of the machine history (cf. the archiving        possibility indicated in FIG. 7). In case of a problem,        therefore, remote diagnosis of a machine is made very easy.        Design problems can be detected in good time by means of        frequency analysis of specific faults and can be eliminated.

The construction of expert networks via ePS host about the processingproblems in extremely different areas can be exchanged. For instance, inthe event of problems, requests to a defined group of other experts canbe addressed directly by the machine.

-   -   Evaluation for the diagnosis of exceptional and fault        situations. In this case, fault lists, existing alarms,        parameters, of the current machine state at the time of the        occurrence of the fault (such as the PLC status, the state of        the I/O, the desired and actual positions as a crash monitor)        are recorded in the manner of a flight recorder and are        available both to the machine operator and to service engineers        from the supplier immediately via the web (service history). At        the same time, via a configurable list, specific persons are        informed about the problem via SMS or e-mail. This makes it        possible to offer the operator a dialog-guided aid for        eliminated faults. If this does not lead to the elimination of        the fault, quick and efficient remote diagnosis is possible        together with the standard measurements described above. If no        success is achieved, an attempt is made to solve the problem        with the aid of a multimedia remote operation. As a result, the        service operations on-site can be replaced, at least partially.        In the event of unavoidable service operations, these can be        better prepared for.

Monitoring of overhaul plans by means of appropriate data exchange withthe host. If appropriate, in the event of non-compliance, the machinecan be temporarily blocked. This can be controlled by appropriateacknowledgement functions.

Visualization of the NC program in the form of tool paths, points andtheir linking to form a virtual workpiece surface (surface feedback),which can be investigated via various illuminations from differentdirections and sources.

Visualization of the control behavior (interpolated points, positioncontroller behavior) in the same way.

-   -   Communication of machine state data to higher-order systems such        as: ERP systems, with the objective of optimizing the overall        fabrication and improving production planning.    -   Saving and archiving configuration data, user data and programs        with the objective of being able to access all versions of the        control data at any time, in order to be able to reconstruct        states, if appropriate, or to detect problematic changes (data        comparison). The possibility of complete backup via remote        server, of interest to relatively small firms.

The product data for automation components (controllers, drives) andother machine components (parts lists, product descriptions, etc.) areavailable at any time via the ePS host.

It is not necessary for any person with expert knowledge to bedispatched to the machine in order to perform the above-describedimprovements, optimizations, etc. It is often even possible, without thesystem according to the invention, for a number of persons with expertknowledge to be sent to the machine. With this invention, the expertknowledge is brought to the machine via the Internet and, at themachine, only the machine operator is available in order to confirmpossible machine (travel) commands.

The use of a browser 23 (cf. FIG. 4) is not absolutely necessary; adirect connection to the Internet or to another communication networkmay also be made. With regard to the abovementioned trace functionality,mention should also be made of the fact that such a function generallysupplies control and drive data in a particularly optimal fashion.However, whether such a functionality is provided directly, or with theinclusion of additional services or modules, generally depends on theapplication. A distinction is generally drawn between a “normal” tracefunctionality, as it is known, in which a trace is started and ended atfixedly defined times or events. A transfer of acquired machine statedata is then initiated only as soon as the trace has been ended. As analternative to this, there is the possibility of providing an “endless”trace functionality, as it is known. In this case, the trace runs as anapplication in the background and a continuous transfer of acquired dataaway from the working computer is carried out (for example to an HMI).

A trace functionality is generally given only read access to the controlcore NCK. Write access, for example by means of a function generator, isinconsistent with the conventional definition of a trace functionalityand, therefore, generally has to be added as an additional function tothe usual trace functionality. This is necessary, for example, when afunction generator and a trace functionality have to be implemented asan externally coupled function for specific automated procedures.

A trace functionality can generally be configured offline. However, assoon as a trace has been initiated, the conditions in the runningoperation may not be changed. For this purpose, the trace must first bestopped or broken off.

Possible functions for a trace in the context of the present inventionare, for example, the commissioning of a machine, fault detection,problems with applications (above all in the case of complexapplications with a plurality of channels and synchronous actions),sporadic problems relating to the running time of the machine, toolbreakage, or logical analyses such as those from telescope or tachometerfunctions.

Depending on the application, there is a large number of items ofinformation to be acquired for the machine state data to be acquired.These include, inter alia:

-   -   system variables, drive signals, PLC flags and various types of        events such as status, status changes or binary signals such as        alarm signals, etc.;

-   access to local user program data (for example NC program, flags in    the PLC program);

-   transferring acquired local data into suitable global variables.

All these data, mentioned by way of example, can be used as a triggerfor the sequence tracking or trace functionality.

Under certain circumstances, there may be specific requirements forcarrying out sequence tracking or trace functionality, for example inconnection with PLC data. For access to PLC peripherals or signals orflags in a user program, it can be advantageous if this is possiblewithout any influence on the PLC itself. Above all, access to userprogram data (I/O, flags, etc.), and the possibility of synchronizingthe starting point for recording machine state data via a user program,is advantageous, in accordance with a further embodiment of theinvention. Another advantageous embodiment of the invention includes upto 32 PLC signals, which can be monitored at the same time within thecontext of sequence tracing or trace functionality. To this end,available buffer data in a user program can also advantageously bestored.

The acquisition of machine state data is advantageously carried out in amanner tailored to the automatic service operated. This is carried outparticularly effectively if only the requisite items of information areacquired and this is done no more often than necessary. In addition, aclear distinction should be drawn between continuous signals andsporadic events. If possible, data compression is carried out during itsacquisition, while taking run-time effects into account. The entirespectrum of machine information is acquired only if the purpose forwhich the data will be acquired is not known or defined. Depending onthe application, preference is given, for example, to ring buffermemories, in which, according to their operating principle, the oldestitems of information or those lying furthest back are overwritten, whilein the case of a wait-loop memory or a queue, as it is known, it isalways the newest information that is overwritten when the wait-loop isfull.

There could be further supplementary information, for example in a timestamp or values from timers, etc. In the case of the analysis of thecauses of critical errors, the sequence tracking or trace functionalitywill be carried out as independently as possible from the malfunction.This means that, during continued operation after a fault, data acquiredbefore the fault will be stored safely. In the ideal case, everyvariable to be acquired in connection with the machine state data willbe provided as a dedicated function with its own time characteristic, inorder to keep the occurrence of data as low as possible.

According to a further advantageous refinement of the invention, theacquisition of machine state data is carried out under time control orevent control. In addition, an additional file or an additional archivecan be generated automatically, which can also preferably containsubprograms. In a trace file, a reference, for example a pointer, tothis archive or this file is then sent. In this way, it is possible forpossible inconsistencies in connection with a manual implementation ofsuch a function to be prevented from the start. For example, manualarchiving can even be carried out several days after the dataacquisition, since it is possible for the configuration already to havechanged during this time. This can also be specified by means of aspecific application, such that conditions do not have to be satisfiedby internal interfaces.

According to a further advantageous refinement of the present invention,changes in the configuration of distributed components are madeautomatically. This also applies to the acquisition and provision ofavailable meta-information (data about data). The human-machineinterface (HMI) can be used in this connection as an interface for aninternal configuration. As a result, a simpler cost-effective expansionfor new signals can also be provided, by the latter being linked withsequence tracking or trace functionality in a straightforward way viathe HMI interface (merge, as it is known).

One possible procedure for controlling what has been outlined abovepreferably provides the following functions:

Starting conditions (manual, NC program, PLC, synchronized,time-controlled, continuous or via external signals) and stop/triggerconditions (manual, NC program, PLC, synchronized, time-controlled,overflow from internal summations or via external signals).

Such trigger conditions are preferably to be set within certain states:

-   for example, trigger by individual bits, by a change in state    variables from a state Z1 to a state Z2 (exactly defined state    transitions) or by text instead of numeric codes;-   by a trigger in the form of uniquely defined NC program commands or    associated command numbers;-   trigger by the nth occurrence of a predefined relevant code.

Nested conditions are likewise possible, such as: condition A must besatisfied, then condition B or condition C and, if condition E issatisfied, data are acquired until condition F occurs.

Following an accident (for example tool breakage) or a stoppage, it isensured that all the necessary resources are available as far aspossible, and as soon as data are transmitted. As soon as a criticalfault has occurred, it is important that a condition associated withthis fault is defined, so that automatic restarting is ruled out.

Suitable preparation of data is preferably carried out at thehuman-machine interface (HMI). In addition, depending on requirements,it is possible to bind an application exclusively to one file.Otherwise, a serial COM link is possible, in order to permit blockwiseaccess via a continuous data stream (without buffering in the file).Among others, three different use classes could and should be operated:

-   -   1. prepared use, such as applications of control software        manufacturers on the human-machine interface (HMI), such as        visualization of a sequence trace, IBN or diagnostic tools    -   2. OEM user (working computer or client applications)    -   3. Internet or web-based services

A sequence trace preferably has a structure that is open to the user.Open and freely accessible interfaces for the configuration includecontrols (start, stop) and analysis possibilities (data format) forOEMs.

According to a further advantageous embodiment of the invention, thedisplay of a sequence trace is carried out in a manner comparable with alogic analyzer oscilloscope. This can be used to display signals fromvarious sources. In addition, references to a specific program modulecan be displayed. Cursor and zoom functions are advantageously alsoprovided. It is beneficial if at least four signals can be made visibleat the same time. In addition, filters are preferably provided whichpermit the selection of signals. Furthermore, differential signals canbe output or important events can be assigned, by which means users withlittle knowledge gain a better understanding of the information ormachine state data acquired.

In order to ensure high robustness during the data acquisition, thefollowing possibilities are particularly suitable:

-   as far as possible, data should be accessible even after a defect.-   sudden faults during sequence tracking should not result in a data    overflow, and suitable reactions in the case of scarce resources    should be provided.-   after the occurrence of a fault, it is ensured that files with    acquired machine state data cannot be deleted at a later time.

In the following, a further selection of possible services or datacontents will be listed:

Machine-related services such as

-   analysis of machine operating times, failure times and capacities

Axis analyses such as

-   individual analysis, status-   simulation of axes-   measurement of the amplitudes

Fourier transformation and generation of Bode diagrams with

-   identification of eigenfrequencies-   trend analyses

Axis optimizations and optimizations of axis parameters such as

-   engagement speed-   acceleration-   jolt-   filter-   KV factor-   friction compensation-   looseness compensation

Checking of machine data such as

-   accuracy and consistency-   consistency of the data memories-   consistency of functions and machine data

Wear analysis such as

-   path accuracy-   trend analyses-   increasing play in the joints-   friction problems (for example lubrication)-   transmission problems between motors and axes

Monitoring of processes with, for example,

-   drive parameters-   instantaneous utilization or capacity-   torques-   jolt-   rotational speed-   temperatures-   trend analyses

Machine inspections with

-   circular shape tests-   measurements of the stiffnesses of-   linearaxes-   C axes

Machine calibrations with

-   feeler gage-   single-axis calibration-   C-axis calibration-   workpiece measurements

Workpiece-related services with

-   workpiece geometry-   measurement of the track fidelity-   trace functionality in relation to the current objective in tabular    or graphical form-   workpiece surface and quality

Process analyses with

-   determination and documentation of the feed speed and cutting speed-   measurement of the cutting force via, for example,-   laser power-   Fourier transformation and frequency observation

Software sales and marketing with

-   supply of new versions-   supply of fault corrections (service packs)-   supply of communication software and hardware for the provision of    services.

The above description of preferred embodiments according to theinvention is given for the purpose of illustration. These exemplaryembodiments are not exhaustive. Nor is the invention restricted to theprecise form indicated; instead numerous modifications and changes arepossible within the context of the technical teaching specified above.One preferred embodiment was selected and described in order to indicatethe basic details of the invention and practical applications, in orderto place those skilled in the art in a position to implement theinvention. A large number of preferred embodiments and furthermodifications come into consideration in the case of specific areas ofapplication.

1. A system for computer-aided handling and management of a numericallycontrolled industrial processing machine, having the following features:a main computer (host 8) to produce and provide machine-related dataand/or services and a machine-side working computer (client 21), whichis connected to the main computer via a data communication link (14) andby means of which (client) machine state data can be acquired in realtime and transmitted to the main computer and by means of whichmachine-related data and/or services generated by the main computer as afunction of such machine state data can be received by means of ananalysis and evaluation unit.
 2. The system for computer-aided handlingand management as claimed in claim 1, the main computer having acommunication link to a higher-order computer system of a machinemanufacturer or manufacturer of machine components, via which access tosystem data of the main computer can be granted to the higher-ordercomputer system by the main computer.
 3. The system for computer-aidedhandling and management as claimed in claim 1 or 2, the machine-sideworking computer (client) having a unique identification means (I) withrespect to the main computer (host), in particular an identificationcode, via which (I) the main computer (host) associates machine statedata received from this working computer with this working computer. 4.The system for computer-aided handling and management as claimed inclaim 1, 2 or 3, the data communication link between the main computer.(host) and the working computer (client) being a connection via anInternet or Intranet.
 5. The system for computer-aided handling andmanagement as claimed in claim 4, it being possible for thedetermination of machine state data on the part of the working computer(client) to be controlled via instructions received from the maincomputer (host) via the Internet or Intranet.
 6. The system forcomputer-aided handling and management as claimed in claim 5, via whichInternet pages or Intranet pages for the user-aided selection of optionsprovided therein can be transmitted from the main computer (host) to theworking computer (client).
 7. A method for computer-aided production andprovision of machine-related data and/or services for a numericallycontrolled industrial processing machine, a main computer (host) and amachine-side working computer (client) communicating via a datacommunication link, having the following method steps: acquisition ofmachine state data on the part of the working computer (client),transmission of the acquired machine state data via the datacommunication link to the main computer (host), production ofmachine-related data and/or services on the part of the main computer(host) as a function of such machine state data and provision of thesemachine-related data and/or services to the working computer (client) orits user.
 8. The method for computer-aided production and provision ofmachine-related data and/or services as claimed in claim 7, machinestate data being acquired in real time on the part of the workingcomputer (client).
 9. The method for computer-aided production andprovision of machine-related data and/or services as claimed in claim 7or 8, a unique identification means (I), in particular an identificationcode, associated with the machine-side working computer (client) beingtransmitted to the main computer (host).
 10. The method forcomputer-aided production and provision of machine-related data and/orservices as claimed in claim 9, the main computer (host) associatingmachine state data received from a working computer with this workingcomputer by using the identification means (I).
 11. The method forcomputer-aided production and provision of machine-related data and/orservices as claimed in one of the preceding claims 7 to 10, the machinestate data comprising program data or servo data or motor data orconverter data or position data or sensor data.
 12. The method forcomputer-aided production and provision of machine-related data and/orservices as claimed in one of the preceding claims 7 to 11, the workingcomputer (client) buffering the acquired machine state data in a storagemeans before said data are transmitted to the main computer (host). 13.The method for computer-aided production and provision ofmachine-related data and/or services as claimed in claim 12, machinestate data stored in the storage means being transmitted via the datacommunication link to the main computer (host) under time control orevent control.
 14. The method for computer-aided production andprovision of machine-related data and/or services as claimed in one ofthe preceding claims 7 to 13, automatic analysis or evaluation ofreceived machine state data being carried out on the part of the maincomputer (host).
 15. A method of creating a database withmachine-related data for a plurality of industrial processing machines,a common main computer (host) performing computer-aided production andprovision of machine-related data and/or services as claimed in one ofthe preceding claims 10 to 14 for a plurality of working computers(clients) associated with the industrial processing machines, a data setwith the machine state data from one of the working computers (clients)being generated in a storage means and the unique identification codeassociated with this working computer being determined, and an item ofinformation corresponding to the identification code being appended tothe data set.
 16. A method for computer-aided provision ofmachine-related data and/or services from a main computer of a serviceprovider to a working computer of a processing machine of a customer viaa network, in particular as claimed in one of the preceding claims 7 to15, the working computer of the processing machine of the customerhaving a system for the control and/or monitoring of the processingmachine and a suitable sensor for acquiring machine state data and beingconnected to the network, having the following method steps:transmission of information relating to the availability ofmachine-related data and/or services from the main computer to theworking computer, receipt of a request for machine-related data and/or aservice from the working computer on the part of the main computer,transmission of information with reference to requisite machine statedata to be acquired by the working computer from the main computer tothe working computer, receipt of data from the working computercontaining the requisite machine state data on the part of the maincomputer, generation of the machine-related data requested by theworking computer and/or the requested service by the main computer andtransmission of the machine-related data requested by the workingcomputer and/or the requested service from the main computer to theworking computer.
 17. The method for computer-aided provision ofmachine-related data and/or services from a main computer of a serviceprovider to a working computer of a processing machine of a customer viaa network as claimed in claim 16, the main computer receiving andstoring information with respect to a payment for requestedmachine-related data and/or services from the working computer.
 18. Themethod for computer-aided provision of machine-related data and/orservices as claimed in claim 16 or 17, in particular for computer-aidedprovision of services for optimization purposes, having the followingfurther method steps: generation of a data structure to accommodate datawith reference to a service, storage of first data in the datastructure, which represent the identity of a customer, in particular ofthe unique identification code, and storage of further data in the datastructure, which represent the identity of the service.
 19. The methodfor computer-aided provision of machine-related data and/or services asclaimed in claim 18, in particular for computer-aided provision ofservices for optimization purposes, having the following further methodsteps: determination of measured data with reference to the serviceprovided to the customer and storage of further data in the datastructure, which represent these measured data.
 20. The method forcomputer-aided provision of machine-related data and/or services asclaimed in one of claims 17 to 19, having the following further methodsteps for registering price information for payment: determination of afirst item of price information as fixed costs of a predeterminedrepeated time period, in particular a monthly time period, determinationof a second item of price information as variable costs as a function ofa service provided.
 21. An apparatus for computer-aided provision ofmachine-related data and/or services on a main computer of a serviceprovider for a working computer of a processing machine of a customervia a network, in particular with a system for computer-aided handlingand management of a numerically controlled industrial processing machineas claimed in one of the preceding claims 1 to 6, the working computerof the processing machine of the customer having a system for thecontrol and/or monitoring of the processing machine and a suitablesensor (16) for acquiring machine state data and being connected to thenetwork, having the following further features on the part of the maincomputer: a means for transmitting information relating to theavailability of machine-related data and/or services from the maincomputer to the working computer and information with reference torequisite machine state data to be acquired by the working computer fromthe main computer to the working computer and the machine-related datarequested by the working computer and/or the requested service from themain computer to the working computer and a means for the receipt of arequest for machine-related data and/or a service from the workingcomputer on the part of the main computer and of data from the workingcomputer containing the requisite machine state data on the part of themain computer and a means for generating the machine-related datarequested by the working computer and/or the requested service by themain computer.
 22. The apparatus for computer-aided provision ofmachine-related data and/or services on a main computer of a serviceprovider as claimed in claim 21, the means for generating themachine-related data requested by the working computer and/or therequested service by means of the main computer comprising an Internetweb server and the main computer being suitably programmed to use it toproduce Internet web pages.
 23. The apparatus for computer-aidedprovision of machine-related data and/or services on a main computer ofa service provider as claimed in claim 21 or 22, the working computer ofthe customer having a unique identification means, in particular anidentification code, for the processing machine, and the main computerhaving a storage means, in particular a database, to accommodateinformation from the working computer in conjunction with theidentification code.
 24. An apparatus for computer-aided provision ofservices for an automation system via a network, in particular with asystem for computer-aided handling and management of a numericallycontrolled industrial processing machine as claimed in one of thepreceding claims 1 to 6 or 21 to 23, having the following features: ameans (22) for loading instructions (24, 25) onto the automation system,the instructions controlling at least one function or another aspect ofthe automation system, a means (23) for receiving customer-relatedsystem data from the automation system via the network, such system databeing collected as a function of the loaded instructions, a means forgenerating suitable services for the automation system as a function ofthe collected customer-related system data and a means for transmittingsuch services to the automation system of the customer via the network.25. The apparatus for computer-aided provision of services for anautomation system via a network as claimed in claim 24, having a meansfor providing a selection of options of the service to the automationsystem of the customer via the network.
 26. The apparatus forcomputer-aided provision of services for an automation system via anetwork as claimed in claim 25, having a means for selecting one of theoptions of the service on the part of the automation system of thecustomer.
 27. The apparatus for computer-aided provision of services foran automation system via a network, as claimed in one of the precedingclaims 21 to 26, the automation system having a network interface forcommunication via the network and for receiving the service information,and a means (machine agent 22) being provided for generatingmachine-executable program sequences (24, 25) on the basis of thereceived services, the network interface and the means for generatingmachine-executable program sequences exchanging data via a predefineddata format.
 28. The apparatus for computer-aided provision of servicesfor an automation system via a network as claimed in claim 27, thenetwork interface comprising an Internet browser (23).
 29. The use of amethod for computer-aided production and provision of machine-relateddata and/or services as claimed in one of the preceding claims 9 to 20for remote commissioning or remote maintenance of an industrial workingmachine.
 30. The use of a method for computer-aided production andprovision of machine-related data and/or services as claimed in one ofthe preceding claims 9 to 20 for carrying out a subset of the followingmeasures: electronic measurement of workpieces, tools and clamping meansfor the diagnosis of problems in the event of deficient workpiecequality or for the dialog-guided correction of the relationships,indication of the relationships of process variables such as laseroutput, feed speed or tool rotational speed and feed speed, analysis ofthe tool paths in the Cartesian coordinate system, with correction orstatements relating to a good part/poor part, monitoring of processvariables with limiting value monitoring and/or correlation monitoring,program analysis by processing a program in a virtual simulation of theprocessing machine, automatic creation of commissioning logs for theseamless documentation of the commissioning state, automatic creation ofservice and maintenance logs for the seamless documentation of themachine history, evaluation for the diagnosis of exceptional and faultsituations, saving and archiving configuration data, user data andprograms for the reconstruction of states or for the detection ofchanges affected by problems.